Disposable absorbent article with side lying leakage improvement

ABSTRACT

An absorbent article having improved leakage protection when the wearer of the absorbent article is lying on their side. The absorbent article has a surge layer in liquid communication with a portion of the garment facing region and a portion of a side edge of the absorbent core.

BACKGROUND

It is desired that the attributes of personal care absorbent articlesinclude low leakage of liquid waste from the absorbent article and a dryfeel to the wearer. However, absorbent articles commonly fail before thetotal absorbent capacity of the absorbent article is utilized. Mostabsorbent articles are designed for a sitting or standing position andhave a target area in the crotch region of the absorbent article forcontainment of liquid waste. The target area is typically centeredwithin the absorbent article for a female wearer and phased forwardwithin the absorbent article for a male wearer. The target area of theabsorbent article may be flanked by containment flaps to further aid incontaining the liquid waste within the target area and within theabsorbent article. The crotch region may also form a bucket away fromthe wearer's body to hold the fluid until it is absorbed by theabsorbent article. When a wearer of an absorbent article is in a sidelying position, however, the absorbent article often leaks liquid wasteat the leg openings, front waist region or back waist region of theabsorbent article. Leakage can occur due to a variety of reasons such assaturation of the absorbent core in the target area, an inability of thetarget area to handle a gush of fluid, and an insufficient rate of fluiduptake by the absorbent core, especially on the second or third liquidsurges.

It has been found that urination can occur at rates as high as 15 to 20milliliters per second and at velocities as high as 280 centimeters persecond. Conventional diaper absorbent structures, such as thosecomprising admixtures of absorbent gelling particles and cellulosicfluffed pulp, may initially uptake fluid at rates of only about 8milliliters per second or less, depending on the web density andconcentration of gelling particles. The initial uptake rates, however,for conventional absorbent articles can deteriorate once they havealready received liquid surges into their absorbent cores. The disparitybetween liquid delivery and uptake rates can result in excessive poolingon the surface of the absorbent core before it is taken up by theabsorbent core. When the wearer of the absorbent article is in a sidelying position, the excess fluid follows gravity down to the containmentflaps of the absorbent article. The containment flaps may be lying downon the bodyside liner of the absorbent article resulting in gaps betweenthe body of the wearer and the containment flaps. The containment flapslying on the bodyside liner also decreases the area in which the excessfluid can pool when the wearer is in a side lying position. The excessfluid, therefore, leaks from the absorbent article through a gap betweenthe containment flaps and the body of the wearer or through a gapbetween the waist regions and the body of the wearer.

Children who wet the bed at night (“nocturnal enuresis”) tend to havehigher leakage rates. The absorbency challenges are significant fornight time child absorbent articles as 70% of children lay on their sideand when they experience nocturnal enuresis, they generally arereleasing a large volume of urine at high velocity within a singleinsult.

Thus, there is a need for an absorbent article with side lying leakageimprovement that is able to create a space where excess fluid can pool,quickly absorb a large amount of liquid waste in the target area andreduce leakage of liquid waste from the absorbent article when thewearer of the absorbent article is in a side lying position.

SUMMARY

In an embodiment, an absorbent article has an absorbent core which has awearer facing region, a garment facing region, and a first side edgeconnecting the wearer facing region and the garment facing region. Theabsorbent article also has a surge layer which has a first portion inliquid communication with a first portion of the garment facing regionof the absorbent core, and a second portion in liquid communication witha portion of the first side edge of the absorbent core. The surge layerof the absorbent article may further have a third portion in liquidcommunication with a first portion of the wearer facing region of theabsorbent core. In an embodiment, the absorbent article may have asecond surge layer which has a first portion in liquid communicationwith a second portion of the garment facing region of the absorbent coreand a second portion in liquid communication with a portion of a secondside edge of the absorbent core. In an embodiment, the second surgelayer may further have a third portion in liquid communication with asecond portion of the wearer facing region of the absorbent core. In anembodiment, the absorbent article further has a third surge layer, aportion of which is in liquid communication with the wearer facingregion of the absorbent core. In an embodiment, the absorbent articlemay further have a core wrap. In an embodiment, the absorbent articlemay further have a pair of containment flaps.

In an embodiment, an absorbent article has an absorbent core which has awearer facing region, a garment facing region, a first longitudinal sideedge connecting the wearer facing region and the garment facing region,a target area; and a surge layer which has a first portion in liquidcommunication with a first portion of the garment facing region of theabsorbent core, a second portion in liquid communication with a portionof the first longitudinal side edge, and a third portion in liquidcommunication with a first portion of the wearer facing region of theabsorbent core; wherein the surge layer is positioned along alongitudinal length of the absorbent core to align with the target areaof the absorbent core. In an embodiment, the target area is positionedin a crotch region of the absorbent article. In an embodiment, thetarget area is positioned between a crotch region and a front waistregion of the absorbent article.

In an embodiment, an absorbent article has an absorbent core which has awearer facing region, a garment facing region, a first longitudinal sideedge connecting the wearer facing region and the garment facing region,a second longitudinal side edge laterally opposite the firstlongitudinal side edge and connecting the wearer facing region and thegarment facing region, and has a a surge layer which has a first portionin liquid communication with a first portion of the garment facingregion of the absorbent core, a second portion in liquid communicationwith a portion of the first longitudinal side edge of the absorbentcore, a third portion in liquid communication with a first portion ofthe wearer facing region of the absorbent core, and a fourth portion inliquid communication with a portion of the second longitudinal side edgeof the absorbent core. In an embodiment, the absorbent article furtherhas a core wrap. In an embodiment, the absorbent article further has apair of containment flaps.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an absorbent article;

FIG. 2 is a plan view of the absorbent article of FIG. 1 in a stretchedand laid flat condition with the bodyside liner facing the viewer andwith portions of the absorbent article partially cut away to reveal theunderlying features;

FIG. 3 is a separated cross-section of the absorbent article of FIG. 1taken laterally through the crotch region of the absorbent article;

FIG. 4 is a separated cross-section of a second embodiment of theabsorbent article of FIG. 1 taken laterally through the crotch region ofthe absorbent article;

FIG. 5 is a separated cross-section of a third embodiment of theabsorbent article of FIG. 1 taken laterally through the crotch region ofthe absorbent article;

FIG. 6 is a separated cross-section of a fourth embodiment of theabsorbent article of FIG. 1 taken laterally through the crotch region ofthe absorbent article; and

FIG. 7 is a separated cross-section of a fifth embodiment of theabsorbent article of FIG. 1 taken laterally through the crotch region ofthe absorbent article.

DETAILED DESCRIPTION

The present disclosure is generally directed towards an absorbentarticle having improved leakage protection when the wearer of theabsorbent article is lying on their side. As a non-limiting example, theabsorbent article has a surge layer in liquid communication with aportion of the garment facing region of the absorbent core and a portionof a side edge such as, for example, a longitudinal side edge, of theabsorbent core. In this non-limiting example, the surge layer provides aspace for liquid waste to collect while it is absorbed into theabsorbent core, such as when the wearer of the absorbent article is inthe side lying position.

Definitions:

The term “absorbent article” refers herein to an article which may beplaced against or in proximity to the body (i.e., contiguous to thebody) of the wearer to absorb and contain various liquid and solidwastes discharged from the body. Such absorbent articles, as describedherein, are intended to be discarded after a limited period of useinstead of being laundered or otherwise restored for reuse. It is to beunderstood that the present disclosure is applicable to variousdisposable absorbent articles including, but not limited to, diapers,training pants, youth pants, swim pants, feminine hygiene products,incontinence products, medical garments, surgical pads and bandages,other personal care or health care garments, and the like withoutdeparting from the scope of the present disclosure.

The term “bonded” refers herein to the joining, adhering, connecting,attaching, or the like, of two elements. Two elements will be consideredbonded together when they are bonded directly to one another orindirectly to one another, such as when each is directly bonded tointermediate elements.

The term “film” refers herein to a thermoplastic film made using anextrusion and/or foaming process, such as a cast film or blown filmextrusion process. The term includes aperture films, slit films, andother porous films which constitute liquid transfer films, as well asfilms which do not transfer liquid.

The term “g/cc” refers herein to grams per cubic centimeter.

The term “gsm” refers herein to grams per square meter.

The term “hydrophilic” refers herein to fibers or the surfaces of fiberswhich are wetted by aqueous liquids in contact with the fibers. Thedegree of wetting of the materials can, in turn, be described in termsof the contact angles and the surface tensions of the liquids andmaterials involved. Equipment and techniques suitable for measuring thewettability of particular fiber materials or blends of fiber materialscan be provided by a Cahn SFA-222 Surface Force Analyzer System, or asubstantially equivalent system. When measured with this system, fibershaving contact angles less than 90 are designated “wettable” orhydrophilic, and fibers having contact angles greater than 90 aredesignated “nonwettable” or hydrophobic.

The term “liquid impermeable” refers herein to a layer or multi-layerlaminate in which the liquid body waste, such as urine, will not passthrough the layer or laminate, under ordinary use conditions, in adirection generally perpendicular to the plane of the layer or laminateat the point of liquid contact.

The term “liquid permeable” refers herein to any material that is notliquid impermeable.

The term “meltblown” refers herein to fibers formed by extruding amolten thermoplastic material through a plurality of fine, usuallycircular, die capillaries as molten threads or filaments into converginghigh velocity heated gas (e.g., air) streams which attenuate thefilaments of molten thermoplastic material to reduce their diameter.Thereafter, the meltblown fibers are carried by the high velocity gasstream and are deposited on a collecting surface to form a web ofrandomly dispersed meltblown fibers. Such a process is disclosed, forexample, in U.S. Pat. No. 3,849,241 to Butin et al. which isincorporated herein by reference. Meltblown fibers are microfibers whichmay be continuous or discontinuous, are generally smaller than about 0.6denier, and are generally self-bonding when deposited onto a collectingsurface. Meltblown fibers used in the present disclosure may becontinuous in length.

The term “non-woven” refers herein to materials and webs of materialwhich are formed without the aid of a textile weaving or knittingprocess.

The term “pliable” refers herein to materials which are compliant andwhich will readily conform to the general shape and contours of thewearer's body.

The term “spunbond” refers herein to small diameter fibers which areformed by extruding molten thermoplastic material as filaments from aplurality of fine capillaries of a spinnerette having a circular orother configuration, with the diameter of the extruded filaments thenbeing rapidly reduced by a conventional process such as that describedin U.S. Pat. No. 4,340,563 to Appel et al., U.S. Pat. No. 3,692,618 toDorschner et al., U.S. Pat. No. 3,802,817 to Matsuki et al., U.S. Pat.Nos. 3,338,992 and 3,341,394 to Kinney, U.S. Pat. No. 3,502,763 toHartmann, U.S. Pat. No. 3,502,538 to Peterson, and U.S. Pat. No.3,542,615 to Dobo et al., each of which is incorporated herein in itsentirety by reference. Spunbond fibers are generally continuous andoften have average deniers larger than about 0.3, and in an embodiment,between about 0.6 and about 10.

The term “superabsorbent” refers herein to a water-swellable,water-insoluble organic or inorganic material capable, under the mostfavorable conditions, of absorbing at least about 15 times its weightand, in an embodiment, at least about 30 times its weight, in an aqueoussolution containing 0.9 weight percent sodium chloride. Thesuperabsorbent materials can be natural, synthetic and modified naturalpolymers and materials. In addition, the superabsorbent materials can beinorganic materials, such as silica gels, or organic compounds, such ascross-linked polymers.

The term “surge layer” refers herein to a layer capable of rapidlyaccepting and temporarily holding liquid body waste to decelerate anddiffuse a surge or gush of liquid body waste and to subsequently slowlyrelease the liquid body waste therefrom into another layer or layers ofthe absorbent article.

The term “thermoplastic” refers herein to a material which softens whenexposed to heat and which substantially returns to a non-softenedcondition when cooled to room temperature.

The term “three-dimensional” refers herein to an absorbent articlesimilar to underwear, shorts or pants in that it has continuous leg andwaist openings that are bounded by material of which the garment ismade. The absorbent article may or may not have manually tearable seams.

Absorbent Article:

Referring to FIG. 1, a disposable absorbent article 10 of the presentdisclosure is exemplified in the form of a wearer's toilet trainingpant. By way of illustration only, various materials and methods forconstructing an absorbent article 10 such as training pants aredisclosed in PCT Patent Application WO 00/37009 published Jun. 29, 2000by A. Fletcher et al.; U.S. Pat. No. 4,940,464 issued Jul. 10, 1990 toVanGompel et al.; and U.S. Pat. No. 5,766,389 issued Jun. 16, 1998 toBrandon et al., which are incorporated herein by reference. While theembodiments and illustrations described herein may generally apply toabsorbent articles manufactured in the machine-direction, it should benoted that one of ordinary skill could apply the information herein toabsorbent articles manufactured in the cross-direction without departingfrom the spirit and scope of the disclosure. The absorbent article 10includes a front waist region 14, a back waist region 16, and a crotchregion 18 interconnecting the front and back waist regions, 14 and 16,respectively. The absorbent article 10 has a pair of laterally oppositeside edges, 20 and 22 (shown in FIG. 2), and a pair of longitudinallyopposite waist edges, respectively designated front waist edge 24 andback waist edge 26. The front waist region 14 is contiguous with thefront waist edge 24 and the back waist region 16 is contiguous with theback waist edge 26.

Referring to FIG. 2, the absorbent article 10 is illustrated in astretched and laid flat configuration. The illustrated absorbent article10 includes a central absorbent assembly 28 which can be rectangular orany other desired shape. The central absorbent assembly 28 includes anouter cover 38 and a bodyside liner 40 bonded to the outer cover 38 in asuperposed relation by suitable means such as, but not limited to,adhesives, ultrasonic bonds, thermal bonds, or other conventionaltechniques. The outer cover 38 defines a length, or longitudinaldirection 42, and a width, or lateral direction 44, which, in theillustrated embodiment, coincide with the length and width of theabsorbent article 10. An absorbent core 46 is disposed between the outercover 38 and the bodyside liner 40. A pair of containment flaps, 48 and50, is secured to the bodyside liner 40 for inhibiting the lateral flowof body wastes. The central absorbent assembly 28 has opposite endedges, 52 and 54, that form portions of the front and back waist edges,24 and 26, respectively, and opposite side edges, 56 and 58, that formportions of the side edges, 20 and 22, respectively, of the absorbentarticle 10. The absorbent core 46 comprises longitudinal side edges, 60and 62 (shown in FIGS. 3-7), which may form portions of the side edges,56 and 58, of the central absorbent assembly 28 and comprises end edges,64 and 66, which may form portions of the opposite end edges, 52 and 54,of the central absorbent assembly 28. The absorbent core 46, therefore,may have a length and width that is the same as or less than the lengthand width of the central absorbent assembly 28.

A pair of laterally opposite front side panels, 30 and 32, extendoutward from the central absorbent assembly 28 at the front waist region14 (thereby forming transversely outer portions of the front waistregion 14, and more broadly in part forming transversely opposite sidesof the training pant). Laterally opposite back side panels, 34 and 36,extend outward from the central absorbent assembly 28 at the back waistregion 16 (thereby forming transversely outer portions of the back waistregion 16, and together with the front side panels, 30 and 32, furtherdefining the sides of the training pant).

To form a three-dimensional absorbent article such as a training pant,corresponding front and rear side panels, for example 30 and 34 (e.g.,the front left side panel and the rear left side panel) are fastenablysecured together using any suitable means such as, but not limited to,adhesives, ultrasonic bonds, thermal bonds, hook and loop, or otherconventional techniques. The side panels may be refastenably securedtogether, or they may be permanently secured together, or they may beformed integrally with each other and with the central absorbentassembly 28. Securing the side panels together provides a central waistopening 68 and a pair of laterally spaced leg openings, 70 and 72.

The front waist region 14 includes the portion of the absorbent article10 that, when worn, is positioned at least in part on the front of thewearer while the back waist region 16 includes the portion of theabsorbent article 10 that, when worn, is positioned at least in part onthe back of the wearer. The crotch region 18 of the absorbent article 10includes the portion of the absorbent article 10 that, when worn, ispositioned between the legs of the wearer and covers the lower torso ofthe wearer. The front side panels, 30 and 32, and the back side panels,34 and 36, include the portions of the absorbent article 10 (and moreparticularly of the front and back waist regions, 14 and 16,respectively) that, when worn, are positioned on the hips of the wearer.The secured side panels thus broadly define the transversely oppositesides of the absorbent article 10 at an engagement seam 74. The waistedges, 24 and 26, of the absorbent article 10 are configured to encirclethe waist of the wearer and together define the central waist opening68. Portions of the central absorbent assembly 28 side edges, 56 and 58,in the crotch region 18 generally define the leg openings 70 and 72.

The absorbent article 10 formed into a three-dimensional absorbentarticle, such as a training pant, is worn by inserting the wearer's feetthrough the central waist opening 68 and the respective leg openings 70and 72, grasping the absorbent article 10 near the central waist opening68 and then pulling the absorbent article 10 up along the wearer's legsuntil the crotch region 18 of the absorbent article 10 fits snuglyagainst the crotch of the wearer.

The central absorbent assembly 28 is configured to contain and/or absorbliquid and solid wastes discharged from the wearer. For example, thecontainment flaps 48 and 50 are configured to provide a barrier to thelateral flow of body exudates. A flap elastic member 76 and 78 can beoperatively joined to each containment flap 48 and 50 in any suitablemanner known in the art. The elasticized containment flaps 48 and 50define a partially unattached edge that assumes an upright configurationin at least the crotch region 18 of the absorbent article 10 to form aseal against the wearer's body. The containment flaps 48 and 50 can belocated along the central absorbent assembly 28 side edges 56 and 58 andcan extend longitudinally along the entire length of the centralabsorbent assembly 28 or can extend partially along the length of thecentral absorbent assembly 28. Suitable construction and arrangementsfor containment flaps 48 and 50 are generally well known to thoseskilled in the art and are described in U.S. Patent No. 4,704,116 issuedNovember 3, 1987 to Enloe, which is incorporated herein by reference.

To further enhance containment and/or absorption of body exudates, theabsorbent article 10 suitably includes a front waist elastic member 80,a rear waist elastic member 82 and leg elastic members 84 and 86, as areknown to those skilled in the art. The waist elastic members 80 and 82can be attached to the outer cover 38 and/or the bodyside liner 40 alongthe opposite central absorbent assembly 28 end edges 52 and 54, and canextend over part or all of the central absorbent assembly 28 end edges52 and 54. The leg elastic members 84 and 86 can be attached to theouter cover 38 and/or the bodyside liner 40 along the opposite centralabsorbent assembly 28 side edges 56 and 58 and positioned in the crotchregion 18 of the absorbent article 10.

Additional details regarding each of the elements of the absorbentarticle 10 described herein may be found below and with reference toFIGS. 1-7.

Outer Cover:

The outer cover 38 can be elastic, stretchable or non-stretchable andmay be a multi-layer laminate structure of which at least one of thelayers is liquid impermeable. In an embodiment, the outer cover 38 canbe suitably stretchable and more suitably elastic in at least thelateral or circumferential direction of the absorbent article 10. Inanother embodiment, the outer cover 38 can be stretchable, and moresuitably elastic, in both the lateral and the longitudinal directions.In an embodiment, the outer cover 38 may be a two layer construction,including an outer layer 88 constructed of a liquid permeable materialand an inner layer 90 constructed of liquid impermeable material bondedtogether by a laminate adhesive 92. Suitable laminate adhesives can beapplied continuously or intermittently as beads, a spray, parallelswirls, or the like. It is to be understood that the outer cover 38 mayinstead be constructed of a single layer of impermeable material withoutdeparting from the scope of this disclosure.

The liquid permeable outer layer 88 of the outer cover 38 can be anysuitable material and may be one that provides a generally cloth-liketexture to the wearer. One example of such material is a 20 gsm spunbondpolypropylene non-woven web. The outer layer 88 may also be constructedof the same materials from which the bodyside liner 40 is constructed asdescribed herein. It is to be understood that it is not necessary forthe outer layer 88 of the outer cover 38 to be liquid permeable.

The liquid impermeable inner layer 90 of the outer cover 38 can beeither vapor permeable (i.e., “breathable”) or vapor impermeable. Theinner layer 90 may be manufactured from a thin plastic film, althoughother liquid impermeable materials may also be used. The liquidimpermeable inner layer 90 (or the liquid impermeable outer cover 38where the outer cover 38 is of a single-layer construction) inhibitsliquid body waste from leaking out of the absorbent article 10 andwetting articles, such as bed sheets and clothing, as well as the wearerand care giver.

Where the outer cover 38 is of a single layer construction, it can beembossed and/or matte finished to provide a more cloth-like appearance.The outer cover 38 can permit vapors to escape from the absorbentarticle 10 while preventing liquids from passing through. A suitableliquid impermeable, vapor permeable material is composed of amicroporous polymer film or a non-woven material which has been coatedor otherwise treated to impart a desired level of liquid impermeability.

Absorbent Core:

The absorbent core 46 is suitably constructed to be generallycompressible, pliable, non-irritating to the wearer's skin and capableof absorbing and retaining liquid body waste, such as urine. Theabsorbent core 46 can be manufactured in a wide variety of sizes andshapes (for example, rectangular, trapezoidal, T-shape, I-shape,hourglass shape, etc.) and from a wide variety of materials. The sizeand the absorbent capacity of the absorbent core 46 should be compatiblewith the size of the intended wearer and the liquid loading imparted bythe intended use of the absorbent article 10. Additionally, the size andthe absorbent capacity of the absorbent core 46 can be varied toaccommodate wearers ranging from infants to adults.

The absorbent core 46 may have a length ranging from about 200, 210,220, 225, 230, 240, 250, 260, 270, 280, 290, 300, 310, 320, 330, 340, or350 mm to about 355, 360, 380, 385, 390, 395, 400, 410, 415, 420, 425,440, 450, 460, 480, 500, 510, or 520 mm The absorbent core 46 may have acrotch width ranging from about 50, 55, 60, 65, or 70 mm to about 75,80, 85, 90, 95, 100, 105, 110, 115, 120, 125, or 130 mm The width of theabsorbent core 46 located within the front waist region 14 and/or theback waist region 16 of the absorbent article 10 may range from about80, 85, 90, or 95 mm to about 100, 105, 110, 115, 120, 125 or 130 mm

In an embodiment, the absorbent article 10 is a diaper having thefollowing ranges of lengths and widths of the absorbent core 46 havingan hourglass shape: the length may range from about 200, 210, 220, 225,240 or 250 mm to about 260, 280, 300, 310, 320, 330, 340, 350, 355, 360,380, 385, or 390 mm; the width of the absorbent core 46 in the crotchregion 18 may range from about 50, 55, or 60 mm to about 65, 70, 75, or80 mm; the width of the absorbent core 46 in the front waist region 14and/or the back waist region 16 may range from about 80, 85, 90, or 95mm to about 100, 105, or 110 mm

In an embodiment, the absorbent article 10 may be a training pant oryouth pant having the following ranges of lengths and widths of theabsorbent core 46 having an hourglass shape: the length may range fromabout 400, 410, 420, 440 or 450 mm to about 460, 480, 500, 510 or 520mm; the width of the absorbent core 46 in the crotch region 18 may rangefrom about 50, 55, or 60 mm to about 65, 70, 75, or 80 mm; the width ofthe absorbent core 46 in the front waist region 14 and/or the back waistregion 16 may range from about 80, 85, 90, or 95 mm to about 100, 105,110, 115, 120, 125, or 130 mm

In an embodiment, the absorbent article 10 is an adult incontinencegarment having the following ranges of lengths and widths of theabsorbent core 46 having a rectangular shape: the length may range fromabout 400, 410 or 415 to about 425 or 450 mm; the width of the absorbentcore 46 in the crotch region 18 may range from about 90, or 95 mm toabout 100, 105, or 110 mm It should be noted that the absorbent core 46of an adult incontinence garment may or may not extend into either orboth the front waist region 14 or the back waist region 16 of theabsorbent article 10.

The absorbent core 46 has a wearer facing region 45 and a garment facingregion 47. Side edges, such as longitudinal side edges, 60 and 62, andsuch as end edges, 64 and 66, connect the wearer facing region 45 to thegarment facing region 47. The absorbent core 46 may be constructed oftwo layers of materials, or in the alternative, may be constructed of asingle layer of materials. In an embodiment, the absorbent core 46comprises an inner layer 102 suitably composed of hydrophilic fibers andan outer layer 104 suitably composed at least in part of a highabsorbency material commonly known as superabsorbent material. In anembodiment, the inner layer 102 of the absorbent core 46 is suitablycomposed of cellulosic fluff, such as wood pulp fluff, and the outerlayer 104 of the absorbent core 46 is suitably composed ofsuperabsorbent hydrogel-forming particles, or a mixture of cellulosicfluff and superabsorbent hydrogel-forming particles. As a result, theinner layer 102 has a lower absorbent capacity per unit weight than theouter layer 104. The inner layer 102 may alternatively be composed of amixture of hydrophilic fibers and superabsorbent material, as long asthe concentration of superabsorbent material present in the inner layer102 is lower than the concentration of superabsorbent material presentin the outer layer 104 so that the inner layer 102 has a lower absorbentcapacity per unit weight than the outer layer 104. It is alsocontemplated that the outer layer 104 may be composed solely ofsuperabsorbent material without departing from the scope of thisdisclosure.

Various types of wettable, hydrophilic fibers can be used in theabsorbent core 46. Examples of suitable fibers include cellulosicfibers, synthetic fibers composed of cellulose or cellulose derivatives,such as rayon fibers; inorganic fibers composed of an inherentlywettable material, such as glass fibers; synthetic fibers made frominherently wettable thermoplastic polymers, such as particular polyesteror polyamide fibers composed of nonwettable thermoplastic polymer, suchas polypropylene fibers which have been hydrophilized by suitable means.The fibers may be hydrophilized, for example, by treatment with asurfactant, treatment with silica, treatment with a material which has asuitable hydrophilic moiety and is not readily removed from the fiber,or by sheathing the nonwettable, hydrophobic fiber with a hydrophilicpolymer during or after formation of the fiber. For example, onesuitable type of fiber is a wood pulp that is a bleached, highlyabsorbent sulfate wood pulp containing primarily soft wood fibers.However, the wood pulp can be exchanged with other hydrophilic fibermaterials, such as synthetic, polymeric, or meltblown fibers or with acombination of meltblown and natural fibers.

Suitable superabsorbent materials can be selected from natural,synthetic, and modified natural polymers and materials. Thesuperabsorbent materials can be inorganic materials, such as silicagels, or organic compounds, such as cross-linked polymers. Cross-linkingmay be covalent, ionic, Van der Waals, or hydrogen bonding. Examples ofsuperabsorbent materials include polyacrylamides, polyvinyl alcohol,ethylene maleic anhydride copolymers, polyvinyl ethers, hydroxypropylcellulose, carboxymal methyl cellulose, polyvinylmorpholinone, polymersand copolymers of vinyl sulfonic acid, polyacrylates, polyacrylamides,polyvinyl pyrrolidone, and the like. Additional polymers suitable forsuperabsorbent material include hydrolyzed, acrylonitrile graftedstarch, acrylic acid grafted starch, polyacrylates and isobutylenemaleic anhydride copolymers and mixtures thereof. The superabsorbentmaterial may be in the form of discrete particles. The discreteparticles can be of any desired shape, for example, spiral orsemi-spiral, cubic, rod-like, polyhedral, etc. Shapes having a largestgreatest dimension/smallest dimension ratio, such as needles, flakes,and fibers are also contemplated for use herein. Conglomerates ofparticles of superabsorbent materials may also be used in the absorbentcore.

The absorbent core 46 overlays the inner layer 90 of the outer cover 38,extending laterally between the leg elastic members, 84 and 86, and issecured to the inner layer 90 of the outer cover 38, such as by beingbonded thereto with adhesive. However, it is to be understood that theabsorbent core 46 may be unsecured to the outer cover 38 and remainwithin the scope of this disclosure.

Core Wrap:

The absorbent core 46 may be partially or completely encompassed by acore wrap 162. The core wrap 162 maintains the integrity and/or shape ofthe absorbent core 46. The core wrap 162 may be well-suited forcontaining absorbent cores which are made at least partially ofparticulate material such as superabsorbent material. The core wrap 162can be composed of a cellulosic material, such as creped material or ahigh wet-strength tissue, a meltblown web, a spunbond web, a carded web,or a combination thereof. Once the core wrap 162 has been wrapped aroundthe absorbent core 46, the core wrap 162 should not unduly expand orstretch as this might cause particulate material to escape from theabsorbent core 46. In an embodiment, the core wrap 162, while in a drystate, should have respective elongation values at peak load in themachine and cross directions of 30 percent or less and 40 percent orless. In an embodiment, the core wrap 162 may have a longitudinal lengththe same as the longitudinal length of the absorbent core 46.

The core wrap 162 is typically wrapped about the absorbent core 46 overthe wearer facing region 45 and the garment facing region 47 as well asthe side edges. In an embodiment, the core wrap 162 completely wrapsaround the absorbent core 46 and is sealed to itself. In an embodiment,the core wrap 162 may be folded over on itself and then sealed using,for example, heat and/or pressure. In an embodiment, the core wrap 162may be composed of separate sheets of core wrap which are utilized toencapsulate the absorbent core 46 and sealed together using a sealingmeans such as an ultrasonic bonder or other thermochemical bonding meansor the use of an adhesive. Additional details regarding the core wrap162 may be found in U.S. Pat. No. 5,458,592 issued Oct. 17, 1995 toAbuto et al. which is herein incorporated by reference. It should benoted that it is not necessary that the absorbent core 46 is encompassedby a core wrap 162.

Surge Layer:

A surge layer, such as surge layer 128 (shown in FIG. 3), having aninner surface 130 and an outer surface 132 is positioned between thebodyside liner 40 and the outer cover 38 to help decelerate and diffusesurges or gushes of liquid body waste penetrating the bodyside liner 40.The inner surface 130 of the surge layer 128 faces the absorbent core 46and the outer surface 132 of the surge layer 128 faces away from theabsorbent core 46. A portion of the inner surface 130 of the surge layer128 is in liquid communication with a portion of at least one of thefollowing: the wearer facing region 45, the garment facing region 47, aside edge, such as longitudinal side edges, 60 and 62, and end edges, 64and 66, and combinations thereof, of the absorbent core 46.

The absorbent article 10 contains at least one surge layer 128. Theabsorbent article 10 may contain more than one surge layer. Theabsorbent article 10 may contain one, two, three, four, five, six,seven, eight, nine, or ten surge layers. In an embodiment in which theabsorbent article 10 contains more than one surge layer, it is to beunderstood that it is not necessary for each surge layer to have thesame configuration as any other surge layer within the absorbent article10. Non-limiting configurations of surge layers are described andillustrated herein. While particular configurations are described andillustrated herein, it is to be understood that additionalconfigurations of surge layers within an absorbent article 10 arepossible without departing from the spirit and scope of this disclosure.

In an embodiment in which the absorbent article 10 contains more thanone surge layer, the multiple surge layers may be in liquidcommunication with each other. In such an embodiment, the multiple surgelayers may be in liquid communication with each other in a region inwhich the surge layers overlap, in a region in which the surge layersare contiguous with each other, and combinations thereof. It is to beunderstood that in an absorbent article 10 having multiple surge layers,the surge layers need not be in liquid communication with each otherand, therefore, the surge layers may be configured in the absorbentarticle 10 to be spaced apart from and not contiguous with each other.

The surge layer(s) may have any longitudinal length dimension as deemedsuitable. In an embodiment, the longitudinal length of the surge layeris the same as the longitudinal length of the absorbent core 46. In suchan embodiment the midpoint of the longitudinal length of the surge layersubstantially aligns with the midpoint of the longitudinal length of theabsorbent core 46. In an embodiment, the longitudinal length of thesurge layer is shorter than the longitudinal length of the absorbentcore 46. In such an embodiment, the surge layer may be positioned to bein liquid communication with the absorbent core 46 at any desiredlocation along the longitudinal length of the absorbent core 46. As anexample of such an embodiment, the absorbent core 46 may contain atarget area where repeated liquid surges typically occur in theabsorbent article 10. The particular location where liquid is dischargedvaries depending on the age and gender of the wearer. For example, malestend to urinate further toward the front end of the absorbent article 10and the target area may be phased forward within the absorbent article10. The female target area is located closer to the center of the crotchregion 18 of the absorbent article 10. As a result, the relativelongitudinal placement of the surge layer within the absorbent article10 can be selected to best correspond with the actual target area ofeither or both categories of wearers. In an embodiment, the absorbentcore 46 may contain a target area centered within the crotch region 18of the absorbent article 10 with the premise that the absorbent article10 would be worn by a female wearer. The surge layer, therefore, may bepositioned along the longitudinal length of the absorbent core 46 suchthat the surge layer is substantially aligned with the target area ofthe absorbent article 10 intended for a female wearer. Alternatively,the absorbent article 10 may contain a target area positioned betweenthe crotch region 18 and the front waist region 14 of the absorbentarticle 10 with the premise that the absorbent article 10 would be wornby a male wearer. The surge layer, therefore, may be positioned alongthe longitudinal length of the absorbent core 46 such that the surgelayer is substantially aligned with the target area of the absorbentarticle 10 intended for a male wearer.

The surge layer(s) may have a longitudinal length from about 120, 130,140, 150, 160, 170, 180, 190, 200, 210, 220, 225, 230, 240, or 250 mm toabout 260, 270, 280, 290, 300, 310, 320, 340, 350, 360, 380, 400, 410,415, 420, 425, 440, 450, 460, 480, 500, 510 or 520 mm

In an embodiment in which the absorbent article 10 is a diaper, thesurge layer may have a longitudinal length from about 120, 130, 140,150, 160, 170, or 180 mm to about 200, 210, 220, 225, 240, 260, 280,300, 310 or 320 mm In such an embodiment, the surge layer may be shorterin longitudinal length than the longitudinal length of the absorbentcore 46 and may be phased from the front end edge 52 of the absorbentcore 46 a distance of from about 15, 20, or 25 mm to about 30, 35 or 40mm In an embodiment in which the absorbent article 10 may be a trainingpant or youth pant, the surge layer may have a longitudinal length fromabout 120, 130, 140, 150, 200, 210, 220, 230, 240 or 250 mm to about260, 270, 280, 290, 300, 340, 360, 400, 410, 420, 440, 450, 460, 480,500, 510 or 520 mm In such an embodiment, the surge layer may have alongitudinal length shorter than the longitudinal length of theabsorbent core 46 and may be phased a distance of from about 25, 30, 35or 40 mm to about 45, 50, 55, 60, 65, 70, 75, 80 or 85 mm from the frontend edge 52 of the absorbent core 46. In an embodiment in which theabsorbent article 10 is an adult incontinence garment, the surge layermay have a longitudinal length from about 200, 210, 220, 230, 240, or250 mm to about 260, 270, 280, 290, 300, 320, 340, 360, 380, 400, 410,415, 425, or 450 mm In such an embodiment, the surge layer may have alongitudinal length shorter than the longitudinal length of theabsorbent article 10 and the surge layer may be phased a distance offrom about 20, 25, 30 or 35 mm to about 40, 45, 50, 55, 60, 65, 70 or 75mm from the front end edge 52 of the absorbent core 46.

The surge layer(s) may have any total width as desired. The total widthof the surge layer is measured with the surge layer in a laid flatconfiguration. The surge layer may have a total width dimension fromabout 20, 25, 30, 35, 40, 45, 50, 55, 60, 70, 80, 90 or 100 mm to about110, 115, 120, 130, 140, 150, 160, 165, 170, 175, 180, 185, 190, 195,200, 210, 220, 230, 240, 250 or 260 mm As will be understood, the totalwidth of the surge layer may vary dependent upon whether the absorbentarticle 10 has a single surge layer or multiple surge layers. The totalwidth of the surge layer may also vary dependent upon the size and shapeof the absorbent article 10 within which the surge layer will be placed.In an embodiment in which the absorbent article 10 is a diaper, thesurge layer may have a total width dimension from about 20, 25, 30, 35,40, 50, 55, 60 or 70 mm to about 80, 90, 100, 110, 115, 120, 130, 140,150, 160, 165, 170, 175, 200, 210 or 220 mm. In an embodiment in whichthe absorbent article 10 may be a training pant or youth pant, the surgelayer may have a total width dimension from about 15, 20, 25, 30, 40,45, 50, 55, 60, 70, 80, 90 or 100 mm to about 110, 115, 120, 130, 140,150, 160, 165, 170, 175, 180, 185, 190, 195, 200, 210, 220, 230, 240,250 or 260 mm In an embodiment in which the absorbent article 10 is anadult incontinence garment, the surge layer may have a total widthdimension from about 20, 25, 30, 35, 40, 45, 50, 55, 60, 70 or 80 mm toabout 90, 100, 110, 115, 120, 130, 140, 150, 160, 165, 170, 175, 180,190, 200 or 220 mm It should be noted that in an absorbent article 10having more than one surge layer, the surge layers may each have thesame total width, may have different total widths or combinationsthereof.

The lateral width of the surge layer(s) is the measure of the portion ofthe surge layer extending in the lateral direction of the absorbentarticle 10 and in liquid communication with either the garment facingregion 47 or the wearer facing region 45 of the absorbent core 46. Thelateral width of a portion of a surge layer in liquid communication withthe wearer facing region 45 of the absorbent core 46 may range fromabout 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55 or 60 mm to about 65,70, 75, 80, 85, 90, 95, 100, 105, 110, 115, 120, 125, or 130 mm In anembodiment in which at least one surge layer is in liquid communicationwith at least a portion of the garment facing region 47 of the absorbentcore 46, it should be noted that the surge layer may be, but is notnecessarily, in liquid communication with the entire garment facingregion 47 of the absorbent core 46. In an embodiment in which theabsorbent article 10 has a single surge layer, the total lateral widthof the portions of a single surge layer in liquid communication with twolaterally opposite portions of the garment facing region 47 of theabsorbent core 46 may range from about 5, 10, 15, 20, 25, 30, 35, 40,45, or 50 mm to about 55, 60, 65, 70, 75, 80, 85, 90, 95, 100, or 110 mmIn an embodiment in which the absorbent article 10 has a single surgelayer, the surge layer may be in liquid communication with the garmentfacing region 47 in a percentage ranging from about 5, 10, 15, 20, 25,30, 35, or 40% to about 45, 50, 55, 60, 65, 70, 75, 80, 85 or 90%. In anembodiment in which the absorbent article 10 has at least two surgelayers in liquid communication with the garment facing region 47 of theabsorbent core 46, each portion of each surge layer in liquidcommunication with the garment facing region of the absorbent core mayhave a lateral width from about 5, 10, 15, 20, 25 or 30 mm to about 35,40, 45, 50, or 55 mm In an embodiment in which the absorbent article hasmore than one surge layer, the combination of surge layers may be inliquid communication with the garment facing region 47 of the absorbentcore 46 in an percentage ranging from about 5, 10, 15, 20, 25, 30, 35 or40% to about 45, 50, 55, 60, 65, 70, 75, 80, 85 or 90%.

It should be understood that the percentage of surge layer in liquidcommunication with the garment facing region 47 of the absorbent core 46may be uniform along the longitudinal length of the absorbent core 46 ormay vary along the longitudinal length of the absorbent core 46. Asnoted above, the absorbent core 46 may be manufactured in a wide varietyof sizes and shapes such as, for example, rectangular, trapezoidal,T-shape, I-shape, hourglass shape, etc. It should be understood that anabsorbent article 10 having a rectangular absorbent core 46 and a surgelayer having uniform lateral width may have no variance in thepercentage of surge layer in liquid communication with the garmentfacing region 47 of the absorbent core 46. It should be understood thatan absorbent article 10 having an absorbent core 46 with an hourglassshape, for example, and a surge layer having uniform lateral width, mayhave variance, in the longitudinal direction, in the percentage of surgelayer in liquid communication with the absorbent core 46 as the width ofthe absorbent core 46 may be wider in the front waist region 14 and backwaist regionl6 than in the crotch region 18. In such an embodiment, thelateral width of the surge layer may be uniform through the front waistregion 14, back waist region and 16 crotch region 18 but the percentageof surge layer in liquid communication with the garment facing region 47of the absorbent core 46 may be smaller in the crotch region 18 than inthe front and back waist regions 14 and 16. In such an embodiment, thesurge layer may be contiguous with the longitudinal side edges, 60 and62, in the front and back waist regions, 14 and 16, respectively, andmay extend beyond the longitudinal side edges, 60 and 62, in the crotchregion 18.

When the surge layer is in a laid-flat condition, the surge layer mayhave a height of equal to or greater than about 1.5, 2, 2.5, 3, 3.5, 4,4.5, or 5 mm The surge layer may have a generally uniform height andcross-sectional area when in a laid-flat condition. Alternatively, thesurge layer may vary in height and cross-sectional area when in alaid-flat condition. The height of the surge layer when in a laid-flatcondition may be any desired height and may be selected dependent uponthe final configuration of the surge layer in the absorbent article 10as well as the age and gender of the wearer. In an embodiment, theabsorbent core 46 may have a height from about 1, 2 or 3 to about 6, 7,or 8 mm In such an embodiment, the placement of the surge layer inliquid communication with the absorbent core 46 in the manner describedherein may result in a total height of the absorbent core 46 and surgelayer ranging from about 4 or 5 mm to about 10, 11 or 12 mm

The surge layer can rapidly accept and temporarily hold the liquid bodywaste prior to slowly releasing the liquid body waste for flow towardthe absorbent core 46. The surge layer can include various types ofwoven and non-woven fabrics, such as spunbond fabrics, meltblownfabrics, bonded carded webs, through-air bonded carded webs, knitfabrics, woven fabrics, airformed fabrics and the like, as well ascombinations thereof. In an embodiment, the surge layer may be anapertured film. The fabrics can be composed of various types of fibers,such as polyolefin fibers, polyester fibers, bicomponent fibers,conjugate fibers, curly fibers, and the like, as well as combinationsthereof. The fibers may be short staple length fibers such as are usedin the airlaying, bonding and carding processes, or longer morecontinuous fibers such as formed in the spunbond process. Typical staplelength fiber lengths may range from about 5, 15, 20, 25, 30, 35 to about40, 45, 50, or 55 millimeters, though lengths outside of this range mayalso be used. As a non-limiting example, airlaying typically involvesusing fibers with lengths in the range of about 5 to about 20millimeters. Fiber diameters typically may range from about 1.5 to about16 denier, and in another embodiment, from about 3 to about 6 denier.The fibers of the surge layer may be crimped, circular or noncircularincluding, for example, bilobal, trilobal, and x-shaped cross-sections.The fibers may be solid or hollow. Additionally, the fibers may be madefrom a single fiber polymer or from multiple polymers such as arecommonly found in biconstituent and bi- or multicomponent fibers. Whenusing bicomponent fibers, fiber cross-sections may include, for example,sheath/core, side-by-side and islands-in-the-sea cross sections. Theresultant fibrous surge layer may be a uniformly mixed homogeneoussingle layer blend of the selected type fiber or fibers.

The surge layer may have various parameters including basis weight, voidvolume, permeability, porosity, surface area per void volume,hydrophilicity, compression resiliency and saturation capacity. In anembodiment, the basis weight of the surge layer is at least about 20gsm. In an embodiment, the basis weight of the surge layer is from about20, 30, 40, 50 or 60 gsm to about 70, 80, 90, 100, 110, 120, 130, 140,150, or 160 gsm. The void volume of the surge layer is a measure of howmuch air space is in the structure. The void volume is measured at 689dynes per square centimeter (0.01 pounds per square inch) and may rangefrom about 40, 45, 50, 55 or 60 to about 80, 85, 90, 95, 100, 105, 110,115, or 120 cubic centimeters per gram of surge layer. The permeabilityindicates the ability of the surge layer to conduct fluid through it.When a fluid initially enters the surge layer, fluid movement isdominated by forced flow from the momentum of the insult velocity of thefluid. Capillarity may not be significant in this flow regime as it maynot have enough time to control the fluid path, thus, fluid flow throughthe surge layer will be controlled by the permeability of the surgelayer on the initial insult. Permeability for the surge layer may rangefrom about 2,000, 4,000, 5,000, 7,000, 8,000 or 9,000 darcies to about10,000, 11,000, 12,000, 13,000, 14,000, or 15,000 darcies.

The porosity of the surge layer is the ratio of the amount of void spacein the surge layer to the total volume of the surge layer. The porosityof the surge layer, as measured at a pressure of 689 dynes per squarecentimeter (0.01 pounds per square inch), may range from about 95 or 97%to about 98 or 99%. The surface area per void volume, with the voidvolume being measured at a pressure of 689 dynes per square centimeter(0.01 pounds per square inch), may range from about 10, 15, 20, or 25 toabout 30, 30, 45 or 50 square centimeters per cubic centimeter.Permeability is the result of fluid having to travel over and aroundfiber surfaces when under forced flow in order to occupy the void spaceswithin the surge layer. Surface area per void volume (SA/VV) indicateshow closely together those fiber surfaces are located to each other.Thus, SA/VV can control the amount of permeability for a surge layer. Ahigh SA/VV value indicates there is a large amount of surface area whichis placed closely together. Increases in SA/VV can be achieved by usingsmaller fibers which increases the surface area per unit weight or bymaking the surge layer more dense which decreases the void volume perunit weight. When SA/VV increases, permeability decreases since fluid isforced to travel over and around more surfaces to get through the surgelayer. If the SA/VV becomes too high, then the permeability will be toolow to allow easy fluid entry into and flow through the surge layer. Inan embodiment, the SA/VV is below about 50 square centimeters per cubiccentimeter.

To ensure rapid uptake of fluid, the overall surge layer should havehydrophilic tendencies. It is desirable that at least a portion of thefibers have a contact angle less than 90 degrees. As a result, a surgelayer will have sufficiently hydrophilic tendencies when the surge layerhas a saturation capacity from about 40, 45, 50, 55, or 60 to about 65,70, 75, or 80 grams of 0.9% saline solution per gram of surge layer. Thesurge layer may have compression resilience, in both the wet and drystates, of at least about 60, 65, 70, 75, 80, or 85%. In such anembodiment, the surge layer will be able to absorb a larger volume offluid upon rapid insult and will not readily collapse once the fluid hasbeen absorbed. A collapse of the surge layer would result in a reducedcapacity for retaining the fluid.

Examples of suitable surge layers are described in U.S. Pat. Nos.5,486,166; 5,490,846; 5,562,650; and 5,364,382, the entire disclosuresof which are hereby incorporated by reference in a manner that isconsistent herewith.

The bodyside liner 40 may be secured to the surge layer such as by beingbonded thereto using a suitable adhesive and to the absorbent core 46,such as by being bonded thereto by additional adhesive. However, it isunderstood that the bodyside liner 40 may be unsecured to the surgelayer and/or to the absorbent core 46 without departing from the scopeof this disclosure.

FIG. 3 is an illustration of a separated cross-section of an embodimentof an absorbent article 10, such as a training pant, comprising twosurge layers 128 and 134. In such an embodiment, a first portion of theinner surface 130 of surge layer 128 and a first portion of the innersurface 135 of surge layer 134 are in liquid communication with firstand second portions, respectively, of the garment facing region 47 ofthe absorbent core 46. Also in such an embodiment, a second portion ofthe inner surface 130 of surge layer 128 and a second portion of theinner surface 135 of surge layer 134 are in liquid communication withportions of the longitudinal side edges, 60 and 62, respectively, of theabsorbent core 46. It is to be understood that in the illustratedembodiment, the inner surfaces 130 and 135, of the surge layers, 128 and134, are not in liquid communication with the same portions of thegarment facing region 47 of the absorbent core 46. The surge layers 128and 134 may extend laterally across and be in liquid communication withthe garment facing region 47 of the absorbent core 46 any width asdesired. With regards to the second portions of the inner surfaces, 130and 135, of the surge layers, 128 and 134, it is to be understood thatthe second portions of the inner surfaces, 130 and 135, of the surgelayers, 128 and 134, need not be in liquid communication with the entirelongitudinal length of the longitudinal side edges, 60 and 62, of theabsorbent core 46.

FIG. 4 is an illustration of a separated cross-section of an embodimentof an absorbent article 10 comprising two surge layers 138 and 140. Insuch an embodiment, a first portion of the inner surface 139 of surgelayer 138 and a first portion of the inner surface 141 of surge layer140 are in liquid communication with first and second portions,respectively, of the garment facing region 47 of the absorbent core 46.Also in such an embodiment, a second portion of the inner surface 139 ofsurge layer 138 and a second portion of the inner surface 141 of surgelayer 140 are in liquid communication with portions of the longitudinalside edges, 60 and 62, respectively, of the absorbent core 46.Additionally, a third portion of the inner surface 139 of surge layer138 and a third portion of the inner surface 141 of surge layer 140 arein liquid communication with first and second portions, respectively, ofthe wearer facing region 45 of the absorbent core 46. It is to beunderstood that in the illustrated embodiment, the inner surfaces 139and 141 of the surge layers, 138 and 140, are not in liquidcommunication with the same portions of the garment facing region 47 orthe wearer facing region 45 of the absorbent core 46. The surge layers138 and 140, may extend laterally across the garment facing region 47 ofthe absorbent core 46 any width as desired. Also, the surge layers 138and 140, may extend laterally across the wearer facing region 45 of theabsorbent core 46 any width as desired. With regards to the secondportions of the inner surfaces, 139 and 141, of the surge layers, 138and 140, it is to be understood that the second portions of the innersurfaces, 139 and 141, of the surge layers, 138 and 140, need not be inliquid communication with the entire longitudinal length of thelongitudinal side edges, 60 and 62, of the absorbent core 46. FIG. 5 isan illustration of a separated cross-section of an embodiment of anabsorbent article 10 comprising two surge layers 144 and 146. In such anembodiment, a first portion of the inner surface 145 of surge layer 144and a first portion of the inner surface 147 of surge layer 146 are inliquid communication with first and second portions, respectively, ofthe garment facing region 47 of the absorbent core 46. Also in such anembodiment, a second portion of the inner surface 145 of surge layer 144and a second portion of the inner surface 147 of surge layer 146 are inliquid communication with portions of the longitudinal side edges, 60and 62, of the absorbent core 46. Additionally, a third portion of theinner surface 145 of surge layer 144 and a third portion of the innersurface 147 of surge layer 146 are in liquid communication with firstand second portions, respectively, of the wearer facing region 45 of theabsorbent core 46. In the illustrated embodiment it will be seen thatthe third portion of the inner surface 145 of surge layer 144 and thethird portion of the inner surface 147 of surge layer 146 are in liquidcommunication with the wearer facing region 45 of the absorbent core 46substantially across the lateral width of the wearer facing region 45 ofthe absorbent core 46. However, it is to be understood that the thirdportions of the inner surfaces, 145 and 147, of the surge layers, 144and 146, do not need to be in liquid communication with the wearerfacing region 45 of the absorbent core 46 substantially across thelateral width of the wearer facing region 45 of the absorbent core 46.It is also to be understood that one of the third portions of the surgelayers, 144 or 146, could be in liquid communication across more of thelateral width of the wearer facing region 45 of the absorbent core 46than the other third portion of surge layer, 144 or 146. With regards tothe second portions of the inner surfaces, 145 and 147, of the surgelayers, 144 and 146, it is to be understood that the second portions ofthe inner surfaces, 145 and 147, of the surge layers, 144 and 146, neednot be in liquid communication with the entire longitudinal length ofthe longitudinal side edges, 60 and 62, of the absorbent core 46.

FIG. 6 is an illustration of a separated cross-section of an embodimentof an absorbent article 10 comprising a single surge layer 150. In suchan embodiment, a first portion of the inner surface 151 of surge layer150 is in liquid communication with a first portion of the garmentfacing region 47 which is contiguous with longitudinal side edge 60. Asecond portion of the inner surface 151 of surge layer 150 is in liquidcommunication with a second portion of the garment facing region 47wherein the second portion of the garment facing region 47 is contiguouswith longitudinal side edge 62. Additionally in this embodiment, a thirdportion of the inner surface 151 of surge layer 150 is in liquidcommunication with longitudinal side edge 60. A fourth portion of theinner surface 151 of surge layer 150 is in liquid communication withlongitudinal side edge 62. Further in such an embodiment, the innersurface 151 of surge layer 150 is in liquid communication with thewearer facing region 45 of the absorbent core 46. As shown in theillustrated embodiment, the inner surface 151 of surge layer 150 is inliquid communication with the wearer facing region 45 of the absorbentcore 46 across the lateral width of the wearer facing region 45 of theabsorbent core 46. With regards to the third and fourth portions of theinner surface 151 of the surge layer 150 in liquid communication withportions of the longitudinal side edges, 60 and 62, respectively, it isto be understood that the third and fourth portions of the inner surface151 of the surge layer 150 need not be in liquid communication with theentire longitudinal length of the longitudinal side edges, 60 and 62, ofthe absorbent core 46.

FIG. 7 is an illustration of a separated cross-section of an embodimentof an absorbent article 10 comprising three surge layers 154, 156, and158. In such an embodiment, a first portion of the inner surface 155 ofsurge layer 154 and a first portion of the inner surface 157 of surgelayer 156 are in liquid communication with the first and secondportions, respectively, of the garment facing region 47 of the absorbentcore 46. Also in such as an embodiment, a second portion of the innersurface 155 of surge layer 154 and a second portion of the inner surface157 of surge layer 156 are in liquid communication with portions of thelongitudinal side edges, 60 and 62, of the absorbent core 46.Additionally, a third portion of the inner surface 155 of surge layer154 and a third portion of the inner surface 157 of surge layer 156 arein liquid communication with first and second portions, respectively, ofthe wearer facing region 45 of the absorbent core 46. The inner surface159 of surge layer 158 is in liquid communication with the wearer facingregion 45 of the absorbent core 46. With regards to the second portionsof the inner surfaces, 155 and 157, of the surge layers, 154 and 156, itis to be understood that the second portions of the inner surfaces, 155and 157, of the surge layers, 154 and 156, need not be in liquidcommunication with the entire longitudinal length of the longitudinalside edges, 60 and 62, of the absorbent core 46. The third surge layer158 may extend across the lateral width of the wearer facing region 45as desired. As such, the third surge layer may extend across the lateralwith the wearer facing region 45 until it is contiguous with the firstand second surge layers, 154 and 156, respectively. Alternatively, thethird surge layer 158 may be separate from and not contiguous with thefirst and second surge layers, 154 and 156, respectively.

Bodyside Liner:

The bodyside liner 40 of the absorbent article 10 overlays the absorbentcore 46 and the outer cover 38 and isolates the wearer's skin fromliquid waste retained by the absorbent core 46. The bodyside liner 40may be secured to the absorbent core 46, such as by being bonded theretoby an adhesive 93. The bodyside liner 40 extends beyond the absorbentcore 46 to overlay a portion of the inner layer 90 of the outer cover 38and is secured thereto, such as by being bonded thereto by adhesive 94,to substantially enclose the absorbent core 46 between the outer cover38 and the bodyside liner 40. The bodyside liner 40 may be slightlynarrower than the outer cover 38, but it is also to be understood thatthe bodyside liner 40 and the outer cover 38 may be of the samedimensions, or the bodyside liner 40 may be sized larger than the outercover 38, without departing from the scope of this disclosure. It isalso contemplated that the bodyside liner 40 may not extend beyond theabsorbent core 46 and may not be secured to the outer cover 38 and/or tothe absorbent core 46. The bodyside liner 40 is suitably compliant, softfeeling, and non-irritating to the wearer's skin and can be lesshydrophilic than the absorbent core 46 to provide a relatively drysurface to the wearer and permit liquid body waste to readily penetratethrough its thickness. Alternatively, the bodyside liner 40 can be morehydrophilic or can have essentially the same affinity for moisture asthe absorbent core 46 to present a relatively wet surface to the wearerto increase the sensation of being wet. This wet sensation can be usefulas a training aid. The hydrophilic/hydrophobic properties can be variedacross the length, width and/or depth of the bodyside liner 40 andabsorbent core 46 to achieve the desired wetness sensation of leakageperformance.

The bodyside liner 40 can be manufactured from a wide selection of webmaterials, such as synthetic fibers (for example, polyester orpolypropylene fibers), natural fibers (for example, wood or cottonfibers), a combination of natural and synthetic fibers, porous foams,reticulated foams, apertured plastic films, or the like. Various wovenand non-woven fabrics can be used for the bodyside liner 40. Forexample, the bodyside liner 40 can be composed of a meltblown orspunbond web of polyolefin fibers. Alternatively, the bodyside liner 40can be a bonded-carded web composed of natural and/or synthetic fibers.The bodyside liner 40 can be composed of a substantially hydrophobicmaterial, and the hydrophobic material can, optionally, be treated witha surfactant or otherwise processed to impart a desired level ofwettability and hydrophilicity. The surfactant can be applied by anyconventional means, such as spraying, printing, brush coating or thelike. The surfactant can be applied to the entire bodyside liner 40 orit can be selectively applied to particular sections of the bodysideliner 40.

A suitable bodyside liner 40 is constructed of a non-woven bicomponentweb. The non-woven bicomponent web can be a spunbonded bicomponent web,or a bonded-carded bicomponent web. An example of a bicomponent staplefiber includes a polyethylene/polypropylene bicomponent fiber. In thisparticular bicomponent fiber, the polypropylene forms the core and thepolyethylene forms the sheath of the fiber. Fibers having otherorientations, such as multi-lobe, side-by-side, end-to-end may be usedwithout departing from the scope of this disclosure.

Also, although the outer cover 38 and bodyside liner 40 of the centralabsorbent assembly 28 can include elastomeric materials, it iscontemplated that the central absorbent assembly 28 may instead begenerally inelastic, wherein the outer cover 38, the bodyside liner 40and the absorbent core 46 are composed of materials which are generallynon-elastomeric. In an embodiment, the bodyside liner 40 can bestretchable, and more suitably elastic. In an embodiment, the bodysideliner 40 is suitably stretchable and more suitably elastic in at leastthe lateral or circumferential direction of the absorbent article 10. Inother aspects, the bodyside liner 40 can be stretchable, and moresuitably elastic, in both the lateral and the longitudinal directions.

Side Panels:

The front side panels 30 and 32 and the back side panels 34 and 36 ofthe absorbent article 10 are bonded to the central absorbent assembly 28in the respective front and back waist regions, 14 and 16, and extendoutwardly beyond the side edges, 56 and 58, of the central absorbentassembly 28. In an example, the front side panels, 30 and 32, can besecured to the inner layer 90 of the outer cover 38, such as beingbonded thereto by adhesive, by pressure bonding, by thermal bonding orby ultrasonic bonding. These side panels, 30 and 32, may also be securedto the outer layer 88 of the outer cover 38, such as by being bondedthereto by adhesive, by pressure bonding, by thermal bonding, or byultrasonic bonding. The back side panels, 34 and 36, may be secured tothe outer and inner layers, 88 and 90 respectively, of the outer cover38 at the back waist region 16 of the absorbent article 10 insubstantially the same manner as the front side panels, 30 and 32.Alternatively, the front side panels, 30 and 32, and the back sidepanels, 34 and 36, may be formed integrally with the central absorbentassembly 28, such as by being formed integrally with the outer cover 38,the bodyside liner 40 or other layers of the absorbent article 10.

For improved fit and appearance, the front side panels, 30 and 32, andthe back side panels, 34 and 36, suitably have an average lengthmeasured parallel to the longitudinal axis of the absorbent article 10that is about 20 percent or greater, and more suitably about 25 percentor greater, of the overall length of the absorbent article 10, alsomeasured parallel to the longitudinal axis. For example, absorbentarticles 10 having an overall length of about 54 centimeters, the frontside panels, 30 and 32, and the back side panels, 34 and 36, suitablyhave an average length of about 10 centimeters or greater, and moresuitably have an average length of about 15 centimeters. Each of thefront side panels, 30 and 32, and back side panels, 34 and 36, can beconstructed of one or more individual, distinct pieces of material. Forexample, each front side panel, 30 and 32, and back side panel, 34 and36, can include first and second side panel portions (not shown) joinedat a seam (not shown), with at least one of the portions including anelastomeric material. Alternatively, each individual front side panel,30 and 32, and back side panel, 34 and 36, can be constructed of asingle piece of material folded over upon itself along an intermediatefold line (not shown).

The front side panels, 30 and 32, and back side panels, 34 and 36, eachhave an outer edge 96 spaced laterally from the engagement seam 74, aleg end edge 98 disposed toward the longitudinal center of the absorbentarticle 10, and a waist end edge 100 disposed toward a longitudinal endof the absorbent article 10. The leg end edge 98 and waist end edge 100extend from the side edges, 56 and 58, of the central absorbent assembly28 to the outer edges 96. The leg end edges 98 of the front side panels,30 and 32, and back side panels, 34 and 36, form part of the side edges,20 and 22, of the absorbent article 10. The leg end edges 98 of theillustrated absorbent article 10 are suitably curved and/or angledrelative to the transverse axis to provide a better fit around thewearer's legs. However, it is understood that only one of the leg endedges 98 can be curved or angled, such as the leg end edge 98 of theback waist region 16, or neither of the leg end edges 98 can be curvedor angled, without departing from the scope of this disclosure. Thewaist end edges 100 are suitably parallel to the transverse axis. Thewaist end edges 100 of the front side panels, 30 and 32, form part ofthe front waist edge 24 of the absorbent article 10, and the waist endedges 100 of the back side panels, 34 and 36, form part of the backwaist edge 26 of the absorbent article 10.

The front side panels, 30 and 32, and back side panels, 34 and 36,suitably include an elastic material capable of stretching laterally.Suitable elastic materials, as well as one described process forincorporating elastic front side panels, 30 and 32, and back sidepanels, 34 and 36, into an absorbent article 10 are described in thefollowing U.S. Pat. No. 4,940,464 issued Jul. 10, 1990 to Van Gompel etal., U.S. Pat. No. 5,224,405 issued Jul. 6, 1993 to Pohjola, U.S. Pat.No. 5,104,116 issued Apr. 14, 1992 to Pohjola, and U.S. Pat. No.5,046,272 issued Sep. 10, 1991 to Vogt et al.; all of which areincorporated herein by reference. As an example, suitable elasticmaterials include a stretch-thermal laminate (STL), a neck-bondedlaminate (NBL), a reversibly necked laminate, or a stretch-bondedlaminate (SBL) material. Methods of making such materials are well knownto those skilled in the art and described in U.S. Pat. No. 4,663,220issued May 5, 1987 to Wisneski et al., U.S. Pat. No. 5,226,992 issuedJul. 13, 1993 to Morman, and European Patent Application No. EP 0 217032 published on Apr. 8, 1987 in the names of Taylor et al., and PCTApplication WO 01/88245 in the name of Welch et al., all of which areincorporated herein by reference. Other suitable materials are describedin U.S. patent application Ser. No. 12/649,508 to Welch et al. and Ser.No. 12/023,447 to Lake et al., all of which are incorporated herein byreference. Alternatively, the front side panels, 30 and 32, and backside panels, 34 and 36, may include other woven or non-woven materials,such as those described above as being suitable for the outer cover 38or bodyside liner 40, mechanically pre-strained composites, orstretchable but inelastic materials.

Containment Flaps:

Containment flaps, 48 and 50, are secured to the bodyside liner 40 ingenerally parallel, spaced relation with each other laterally inward ofthe leg openings, 70 and 72, to provide a barrier against the flow ofurine to the leg openings, 70 and 72. The containment flaps, 48 and 50,extend longitudinally from the front waist region 14 of the absorbentarticle 10, through the crotch region 18 to the back waist region 16 ofthe absorbent article 10. Each containment flap, 48 and 50, comprises anon-woven layer 110 and a film layer 112 secured to the non-woven layer110, such as by being bonded thereto by adhesive 114. Flap elastics, 76and 78, are secured by suitable adhesive 120 between the non-woven layer110 and the film layer 112, generally at a distal end 122 of thecontainment flaps, 48 and 50, with the non-woven layer 110 being foldedover the flap elastics, 76 and 78, and the film layer 112 at the distalend 122. The containment flaps, 48 and 50, are secured to the bodysideliner 40 by a seam of adhesive 124 to define a proximal end 126 of thecontainment flaps, 48 and 50.

The flap elastics, 76 and 78, as illustrated, comprise three strands ofelastomeric material extending longitudinally along the distal ends 122of the containment flaps, 48 and 50, in generally parallel, spacedrelation with each other. The elastic strands are secured between thenon-woven layer 110 and the film layer 112 while in an elasticallycontractible condition such that contraction of the strands gathers andshortens the distal ends 122 of the containment flaps, 48 and 50. As aresult, the elastic strands bias the distal ends 122 of each containmentflap, 48 and 50, toward a position spaced from the proximal end 126 ofthe containment flaps, 48 and 50, so that the containment flaps, 48 and50, extend away from the bodyside liner 40 in a generally uprightorientation of the containment flaps, 48 and 50, especially in thecrotch region 18 of the absorbent article 10, when the absorbent article10 is fitted on the wearer. It is understood, however, that thecontainment flaps, 48 and 50, may be omitted from the absorbent article10 without departing from the scope of this disclosure.

Leg Elastics:

Leg elastic members, 84 and 86, are secured between the outer and innerlayers, 88 and 90, respectively, of the outer cover 38, such as by beingbonded therebetween by a laminate adhesive 92, generally adjacentlateral outer edges, 106 and 108, of the inner layer 90 of the outercover 38. Alternatively, the leg elastic members, 84 and 86, may bedisposed between other layers of the absorbent article 10. A widevariety of elastic materials may be used for the leg elastic members, 84and 86. Suitable elastic materials include sheets, strands or ribbons ofnatural rubber, synthetic rubber, or thermoplastic elastomericmaterials. The elastic materials can be stretched and secured to asubstrate, secured to a gathered substrate, or secured to a substrateand then elasticized or shrunk, for example with the application ofheat, such that the elastic retractive forces are imparted to thesubstrate.

Flow Control Layer:

A flow control layer (not shown) may be disposed between the inner andouter layers, 102 and 104, respectively, of the absorbent core 46 toretard the rate at which urine received into the absorbent core 46passes from the inner layer 102 to the outer layer 104. The flow controllayer may have a width and length substantially the same as the widthsand lengths of the inner and outer layers, 102 and 104, respectively, ofthe absorbent core 46. However, it is to be understood that the flowcontrol layer may be narrower and/or shorter than the inner and outerlayers, 102 and 104, respectively, or wider and/or longer than the innerand outer layers, 102 and 104, respectively without departing from thescope of this disclosure. The flow control layer may be constructed ofeither an impermeable material or a permeable material, it beingunderstood that the rate at which urine passes from the inner layer 102of the absorbent core 46 to the outer layer 104 of the absorbent core 46is generally a function of the permeability of the flow control layer.As an example, a suitable material from which the flow control layer maybe constructed is a polypropylene or polyethylene film having aperturesformed therein to permit urine to flow therethrough.

The apertures may be sized in the range of about 1 mm to about 10 mm andthe aperture density of the film may be less than or equal to about 14apertures per square inch of the film. The thickness of the film may beless than or equal to about 0.003 inches.

Another suitable material for construction of the flow control layer isa meltblown, hydrophobic non-woven material. The material suitably has abasis weight of about 0.6 ounces per square yard and a thickness of lessthan or equal to about 1 mm It is also contemplated that the flowcontrol layer may be constructed of other permeable materials withoutdeparting from the scope of this disclosure.

As another example, a suitable impermeable material from which the flowcontrol layer may be constructed is a film material, such as apolyethylene or polypropylene film, devoid of apertures to severelyretard the flow of urine from the inner layer 102 of the absorbent core46 to the outer layer 104 of the absorbent core 46. Urine received bythe inner layer 102 of the absorbent core 46 is instead directed by theflow control layer to migrate outward (e.g., through the inner layer 102of the absorbent core 46) toward peripheral edges of the flow controllayer and then around the edges thereof to the outer layer 104 of theabsorbent core 46. In the interests of brevity and conciseness, anyranges of values set forth in this disclosure contemplate all valueswithin the range and are to be construed as support for claims recitingany sub-ranges having endpoints which are whole number values within thespecified range in question. By way of hypothetical example, adisclosure of a range of from 1 to 5 shall be considered to supportclaims to any of the following ranges: 1 to 5; 1 to 4; 1 to 3; 1 to 2; 2to 5; 2 to 4; 2 to 3; 3 to 5; 3 to 4; and 4 to 5.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm ”

All documents cited in the Detailed Description are, in relevant part,incorporated herein by reference; the citation of any document is not tobe construed as an admission that it is prior art with respect to thepresent invention. To the extent that any meaning or definition of aterm in this written document conflicts with any meaning or definitionof the term in a document incorporated by references, the meaning ordefinition assigned to the term in this written document shall govern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. An absorbent article comprising: a. an absorbentcore comprising: i. a wearer facing region; ii. a garment facing region;iii. a first side edge connecting the wearer facing region and thegarment facing region; b. a surge layer comprising: i. a first portionin liquid communication with a first portion of the garment facingregion of the absorbent core; and ii. a second portion in liquidcommunication with a portion of the first side edge of the absorbentcore; wherein the absorbent article further comprises a second surgelayer; and wherein the second surge layer comprises a first portion inliquid communication with a second portion of the garment facing regionof the absorbent core and a second portion in liquid communication witha portion of a second side edge of the absorbent core.
 2. The absorbentarticle of claim 1 wherein the surge layer further comprises a thirdportion in liquid communication with a first portion of the wearerfacing region of the absorbent core.
 3. The absorbent article of claim 1wherein the side edge of the absorbent core is a longitudinal side edge.4. The absorbent article of claim 1 wherein the side edge of theabsorbent core is an end edge.
 5. The absorbent article of claim 1wherein the second surge layer further comprises a third portion inliquid communication with a second portion of the wearer facing regionof the absorbent core.
 6. The absorbent article of claim 1 wherein theabsorbent article further comprises a third surge layer.
 7. Theabsorbent article of claim 6 wherein the third surge layer is in liquidcommunication with the wearer facing region of the absorbent core. 8.The absorbent article of claim 1 further comprising a core wrap.
 9. Theabsorbent article of claim 1 further comprising a pair of containmentflaps.